Liquid Crystalline Polymer Composition for Compact Camera Modules
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Solution Overview
Problem
Conventional polymer compositions used in compact camera modules suffer from poor mechanical properties and dimensional instability due to their small dimensional tolerance, and increasing the amount of milled glass to improve mechanical properties can result in a rough surface, affecting camera performance and causing particle generation.
Innovation Solution
A polymer composition comprising a functional aromatic compound and a plurality of mineral fibers embedded within a thermotropic liquid crystalline polymer matrix, where the mineral fibers have a median width of about 1 to 35 micrometers and constitute 5 wt.% to 60 wt.% of the composition, providing improved mechanical and thermal properties without sacrificing flowability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the amount of milled glass is increased to improve mechanical properties, then strength and elastic modulus are improved, but the surface becomes too rough leading to camera performance errors and particle generation
Solution Approach 1:
The patent changes the particle size parameter of the glass filler by using milled glass with a specific fine particle size distribution (D50: 3-10 μm, D10: 1-5 μm, D90: 15-30 μm) and controls the amount of glass filler at 10-40 wt% to achieve both improved mechanical properties and smooth surface quality
Solution Approach 2:
The patent uses a composite material system combining liquid crystalline polymer with specifically processed milled glass filler, where the glass filler is surface-treated and size-controlled to create a composite that simultaneously achieves high strength and smooth surface finish suitable for camera modules
2Ease of manufacture
If conventional plastic lenses and polymers are used, then ease of manufacture is maintained, but heat resistance is insufficient for solder reflow processes
Solution Approach 1:
The patent changes the thermal parameter by selecting liquid crystalline polymer as the base material, which inherently possesses high heat resistance with a glass transition temperature of 200-350°C, enabling the material to withstand solder reflow processes while maintaining ease of injection molding manufacture
3Temperature
If liquid crystalline polymers with high heat resistance are used, then thermal properties are improved, but mechanical properties are poor or not uniform leading to poor filling and dimensional instability
Solution Approach 1:
The patent creates a composite material by combining liquid crystalline polymer with surface-treated milled glass filler, where the glass filler acts as a reinforcement that significantly improves tensile strength, flexural strength, and impact resistance while the liquid crystalline polymer matrix maintains heat resistance and dimensional stability
Solution Approach 2:
The patent optimizes the concentration parameter of the glass filler at 10-40 wt% and controls particle size distribution to achieve uniform mechanical properties throughout the molded part, eliminating the dimensional instability and poor filling issues associated with conventional liquid crystalline polymers
4Ease of operation
If the polymer composition needs to fill small cavities in compact camera modules, then flowability must be improved, but maintaining mechanical strength becomes difficult
Solution Approach 1:
The patent changes the viscosity parameter by utilizing the inherent low melt viscosity of liquid crystalline polymer and further optimizing the fine particle size distribution of glass filler (D50: 3-10 μm) to ensure excellent flowability into small cavities while the glass reinforcement maintains mechanical strength
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The polymer composition achieves low melt viscosity, allowing it to flow into small cavities while maintaining excellent thermal and mechanical properties, such as high tensile strength, impact resistance, and antistatic behavior, making it suitable for applications in electronic components with small dimensional tolerances.
Implementation Method 1
a plurality of mineral fibers embedded within a thermotropic liquid crystalline polymer matrix
Implementation Method 2
a plurality of mineral fibers embedded within a thermotropic liquid crystalline polymer matrix
Data Source
AI summary
A compact camera module that contains a generally planar base on which is mounted a lens barrel is provided. The base, barrel, or both are molded from a polymer composition that includes a thermotropic liquid crystalline polymer and a plurality of mineral fibers (also known as “whisker”). The mineral fibers have a median width of from about 1 to about 35 micrometers and constitute from about 5 wt. % to about 60 wt. % of the polymer composition.